Continuous carbonaceous matter thermolysis and pressurized char activation with hydrogen production

A system for continuous, concurrent production of activated carbon, hydrogen, process steam, and electric power from carbonaceous matter, comprising:

• a thermolysis reactor, wherein carbonaceous matter is processed in individually temperature-controlled zones for sequentially drying, torrefying, pyrolysing, and devolatilizing the carbonaceous matter to produce char and volatile materials, the thermolysis reactor comprising
• a carbonaceous matter inlet,
• a char outlet,
• means for moving the carbonaceous matter from the carbonaceous matter inlet to the char outlet,
• means for admitting steam at various locations within the zones for sequentially drying, torrefying, pyrolysing, and devolatilizing the carbonaceous matter, the steam acting variously to facilitate chemical reactions, to sweep volatile materials out of the thermolysis reactor and to provide controlled thermal energy,
• a first radiant electric heat distribution system acting to control the temperature within a devolatilization zone, and
• an array of volatile materials outlets;
• and
• a pressurized activation reactor;
• the pressurized activation reactor, wherein the char is reacted with pressurized steam to produce activated carbon and pressurized synthesis gas, the pressurized activation reactor comprising:
• a char inlet integrally connected to the char outlet of the thermolysis reactor and configured to receive char from the char outlet,
• an activated carbon outlet,
• means for moving the char from the char inlet to the activated carbon outlet,
• means for admitting steam, the steam acting as a reactant for char activation,
• a second radiant electric heat distribution system acting to provide an endothermic heat of reaction, and
• a pressurized synthesis gas outlet;
• separation means at the junction of the thermolysis reactor and the pressurized activation reactor acting to effectively isolate the interior environment of the thermolysis reactor from the interior environment of the pressurized activation reactor while allowing passage of the char from the thermolysis reactor into the pressurized activation reactor;
• means for admitting carbonaceous feed into the thermolysis reactor and for discharging activated carbon from the pressurized activation reactor while maintaining various working pressures therein and minimizing the ingress of air from and egress of gases and vapors to atmosphere;
• means for recovering heat from the pressurized synthesis gas by generating steam while cooling and dehumidifying the pressurized synthesis gas and producing cooled and dehumidified pressurized synthesis gas;
• a hydrogen purification system producing purified hydrogen, and combustible tail gas, from the cooled and dehumidified pressurized synthesis gas;
• means for compression and storage of the purified hydrogen;
• a power island comprising means for combustion, process steam raising, heat exchange, and electric power generation, fueled by the volatile materials discharged from the thermolysis reactor and the tail gas discharged from the hydrogen purification system;
• means for delivering electric power from the power island to the first radiant electric heat distribution system of the thermolysis reactor and the second radiant electric heat distribution system of the pressurized activation reactor;
• and
• means for delivering steam from the power island to the thermolysis reactor and the pressurized activation reactor, and steam from the means for recovering heat from the pressurized synthesis gas to the pressurized activation reactor.